Mattress

ABSTRACT

A mattress including a base layer, at least one intermediary layer, and a top layer. The base layer is constructed from a foam material defining an Indentation Level Deflection (ILD) Rating from 25 to 35 pounds, and defines a thickness of between four and eight inches (4″-8″), and having a density from 1 to 4 lb/ft3. Each intermediary layer is constructed from a foam material defining an ILD Rating of between 10 and 25 and defines a thickness from 1.5″ to 3″, and having a density from ˜2 to ˜4 lb/ft3. A top layer is fabricated from a vertically-oriented synthetic memory fiber blend comprised of bi-copolymer fibers and fibers having spring-like molecular structure. The top layer defines a thickness of between 0.75″ and 1.25″ and a weight of between about 200 to about 500 grams per square yard. A cover layer may be disposed above said top layer, the cover layer being fabricated from a selected foam material, and defining a thickness of up to about one inch. A cover member configured to closely and selectively receive the various layers of the mattress may be provided. The cover member may be being provided with at least one handle for assisting in movement and transport of said mattress.

RELATED APPLICATIONS

This application claims the benefit of Provisional Patent Application No. 62/305,756, entitled “Mattress”, filed on Mar. 9, 2016, the contents of which are incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure is directed to an improved mattress construction. The improved mattress is of a multilayered construction.

BACKGROUND

Traditional sleeping surfaces in the form of mattresses have been used for many years. Mattresses have evolved to address many problems associated with sleep, including weight distribution, pressure points, temperature, and the like. Materials have also been developed in an attempt to improve on the quality of sleep provided for a particular user.

Common mattress constructions are numerous. While air mattresses and water mattresses are common, the most common are coil mattresses and, more recently, foam mattresses. Foam mattresses include either single- or multi-layer constructions. In multi-layer constructions, a soft top layer of a memory foam mattress or bed topper can be a real advantage in pressure point reduction. However, a foam layer that is too soft, or too thick of a very soft surface layer, especially without enough support underneath, can be problematic for low back sufferers. Thus, some memory foam mattresses use a layered effect that properly offers a supple enough surface to disburse pressure points, but gradually firms up in the layers below, with a very resilient support base used in the final layer.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, together with the detailed description below, are incorporated in and form part of the specification, and serve to further illustrate embodiments of concepts that include the claimed invention, and explain various principles and advantages of those embodiments.

FIG. 1 is an isometric cross-section view of a preferred embodiment of a mattress of the present invention;

FIG. 2 is an isometric cross-section view of an alternate embodiment of a mattress of the present invention;

FIG. 3 is an isometric cross-section view of a further alternate embodiment of a mattress of the present invention;

FIG. 4 is a top isometric view of a mattress of the present invention illustrating a cover encasing the mattress core;

FIG. 5 is an isometric view of the a mattress of the present invention showing the bottom side of the cover of FIG. 4 further illustrating handles and a zipper;

FIG. 6 is a perspective view of a mattress of the present invention shown in a folded and compressed state and stored in a container;

FIG. 7 is a perspective view of a mattress of the present invention shown in a folded and compressed state;

FIG. 8 is a perspective view of a mattress of the present invention shown in a folded state;

FIG. 9 is a perspective view of a mattress of the present invention shown expanding from the folded state illustrated in FIG. 8;

FIG. 10 is a perspective view of a mattress of the present invention shown installed on a conventional bed frame;

FIG. 11 is a perspective view of a mattress of the present invention shown installed on a conventional bed frame; and

FIG. 12 is a perspective view of a mattress of the present invention shown installed on a conventional bed frame.

Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.

The apparatus and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

DETAILED DESCRIPTION

The present invention is a mattress 10 constructed with a plurality of independent layers, each constructed to define a selected characteristic. The mattress 10 defines a total thickness of between approximately 4.75″ and approximately 15.25″. However, it is envisioned that the mattress 10 could define a thickness of less than 4.75″ or greater than 15.25″.

A bottom layer 20 is provided as a base or structure layer. The base layer 20 is constructed from a responsive polymer structure that is designed to offer a superior structure. The base layer 20 defines a thickness of between four and eight inches (4″-8″). However, it will be understood that the base layer 20 may define a thickness of less than four inches or greater than eight inches.

The base layer 20 is constructed of a foam material defining an Indentation Level Deflection (ILD) Rating of between 25 and 35 pounds. The ILD rating is an indication of how hard or soft a material is. The ILD rating is the number of pounds required to achieve a 25% compression of a foam layer using a 50 square inch indentation. Thus, a higher ILD rating is indicative of a firmer material and, conversely, the lower ILD rating is indicative of a softer material. The ILD rating is synonymous with the Indentation Force Deflection (IFD) Rating, which is still in use but was developed for sole the purpose of grading polyurethane foam.

The density of the base layer 20 of the preferred embodiment is between one and four pounds per cubic feet (1-4 lb/ft³).

A top layer 30 is secured to the base layer 20 in a conventional manner. In the embodiment illustrated in FIG. 1, the top layer 30 is the uppermost layer, closest to the body of the person(s) lying on the mattress 10. The top layer 30 is constructed with selected materials and in such as a way as to provide an enhanced comfort layer. The preferred material is fabricated from a vertically-oriented synthetic memory fiber blend. This material is manufactured by orienting the fibers vertically as opposed to horizontally, thereby enhancing various characteristics of the material. Among these are its compressibility and breathability, even in a compressed state. The top layer 30 provides gentle resilience and sure shape recovery to the mattress. To this end, the memory fibers blends bi-copolymer fibers with fibers having spring-like molecular structure. It is the product of a world leading advancement in polymer, fibers process technology and expertise. The top layer 30 offers superior breathability that provides for improved air flow and cooling factor, resulting in less heat retention than existing standard foam mattresses. The material comprising the top layer 30 of the preferred embodiment provides other environmental advantages. Namely, it is environmentally friendly, 100% recyclable and is hypoallergenic. The top layer 30 does not emit dangerous fumes, is mildew-resistant, mold-resistant, and flame-resistant. Because of the vertical orientation of the fibers, the top layer 30 drains fluids and is highly breathable. One satisfactory material is Polyester.

The top layer 30 defines a thickness of between 0.75″ and 1.25″. The top layer 30 of the preferred embodiment defines a weight of between approximately 200 to 500 grams per square yard.

The mattress 10 of the present invention may further include one or more intermediary layers of a selected foam material. Illustrated in FIG. 2, an alternative construction of a mattress 10′ includes a second layer 22 and a third layer 24 disposed between the base layer 20 and the top layer 30. It will be understood that either of the second and third layers 22,24 could be eliminated in further alternate mattress embodiments. In these embodiments, the top layer 30 and any intermediary layers 22,24 define a combined thickness at least equal to the cradle needed, and, more preferably, thicker.

In the illustrated embodiment, the second layer 22 is secured to the base layer 20 in a conventional manner, as will be disclosed hereinafter. The second layer 22 is constructed to provide comfort and pressure point distribution. The second layer 22 is constructed from a foam material having a highly-open, cool, and responsive polymer structure that is designed to offer a superior alternative to latex or coil springs while providing outstanding pressure relief properties. The thickness of the second layer 22 in the preferred embodiment is 1.5″, but may be as thick as approximately 3″. However, it will be understood that the second layer 22 may define a thickness of greater than three inches. The second layer is constructed of a foam material defining an ILD Rating of between 10 and 25. The density of the second layer 22 of the preferred embodiment is between two and four pounds per cubic feet (2-4 lb/ft³).

A third layer 24 is secured to the second layer 22 in a conventional manner. The third layer 24 is provided primarily to adapt the mattress to the contour of the person or persons lying on the mattress. The third layer 24 is constructed from a foam material having a highly-open, cool, and responsive polymer structure that is designed to offer a superior alternative to latex or coil springs while providing outstanding pressure relief properties. The thickness of the third layer 24 in the preferred embodiment is 1.5″, but may be as thick as approximately 3″. However, it will be understood that the third layer 24 may define a thickness of greater than three inches. The third layer 24 is constructed of a foam material defining an ILD Rating of between 10 and 25. In the preferred embodiment, the ILD Rating of the third layer 24 is lower, or softer, than that of the second layer 22. The density of the third layer 24 of the preferred embodiment is between two and four pounds per cubic feet (2-4 lb/ft³).

In this type of construction, the top layer 30 is designed to do all the work of forming a pressure relieving cradle and supporting the recessed lumbar area. The base layer 20 and intermediary layers 22,24 are provided for keeping the spine in alignment by preventing any further sinking down by the heavier parts of the body. Each individual layer 22, 24, 30 has all the qualities that are necessary by itself, as it does not “borrow” qualities from the layer 20, 22, 24, respectively, below it. For pressure relief, it needs enough softness and point elasticity, and for lumbar support it needs a higher sag factor and resiliency. For example, for a 3″ cradle for good pressure relief, the top layer 30 and intermediary layers 22,24 are collectively configured to define a thickness of between approximately 3″-3.5″. For a 2″ cradle for pressure relief, the top layer 30 and intermediary layers 22,24 are collectively configured to define a thickness of between approximately 2″-2.5″. The top layer 30 and intermediary layers 22,24 of the preferred embodiment define a combined thickness at least equal to the cradle needed, and, more preferably, thicker. In one preferred embodiment, the mattress includes a base layer 20 defining a thickness of six inches (6″), an intermediary layer 22 defining a thickness of three inches (3″), and a top layer 30 defining a thickness of one inch (1″).

In a further preferred embodiment illustrated in FIG. 3, a mattress 10″ a cover layer 32 is provided to be placed above the top layer 30 in a conventional manner. The cover layer 32 is provided for additional comfort. The cover layer 32 is fabricated from a selected foam material and defines a thickness of up to one inch (1″). The foam material is selected from memory foam, regular foam, and latex. The cover layer 32 may be secured to the top layer and integrally with the mattress. Alternatively, the cover layer 32 may be removably placed on top of either of the mattresses 10,10′ illustrated in FIGS. 1 and 2, respectively.

The individual layers 20, 22, 24, 30, 32 are secured to each other as discussed above in a conventional manner. In one embodiment, each successive layer 22, 24, 30, 32 is glued to the preceding layer 22, 24, 30, 32 (the top layer 30 is secured to the base layer 20, or the second or third layer 22,24 if either or both are provided, etc.) using a water-based adhesive having low odor and being a low-volatile, organic compound. In this assembly method, the mattress 10, 10′, 10″ is cured for from approximately 6 hours to approximately 18 hours. It is then inserted into a fire-retardant sewn fabric. It is also covered by an aesthetic cover made of special selected material that improves air flow, cooling and wicking out the humidity coming from the body.

In one preferred embodiment of the present invention, as best illustrated in FIG. 4, a cover 40 is provided to encase the various layers 20, and 30, and optionally 22, 24, and 32, as provided in the particular mattress 10, 10′, 10″. The cover 40 of the preferred embodiment is fabricated from a specially-weaved fabric using a Micro Tencel™ fiber yarn. This new botanic fiber renders the cover more absorbent than cotton, softer than silk and cooler than linen.

The cover 40 fabric or the yarn from which the fabric is produced is also treated with Ferran Ice™ to bring the hydrophilic property to a higher level in order to have the best comfort level.

The upper section 44 of the cover side walls 42 is composed of a breathable mesh-type fabric to enhance air flow and breathability qualities. The width of the upper section 44 is from approximately one inch to approximately four inches The cover 40 of the preferred embodiment is of a fabric weight of from approximately 140 to approximately 900 grams per square yard. The fabric may be designed with any pattern to the taste of the user.

At least one handle 48 may be provided and secured to the cover 40 in a conventional fashion. In the illustrated embodiment of FIG. 5, four handles 48 are mounted on the bottom surface 46 of the cover 40, with two handles 48 being spaced apart and mounted on either of the long edges of the mattress 10. The handles 48 provide a mechanism to handle the mattress 10 during transport, set up and take down thereof. The handles 48 of the illustrated embodiment are fabricated from conventional flexible materials such as but not limited to nylon webbing, and may be folded under the mattress 10 in order to conceal them from view ad so as not to provide a hindrance for the placement of a conventional mattress pad or bed sheets. However, it will be understood by those skilled in the art that the handles 48 do not alter the function of the mattress 10 and are therefore not required as a part of the present invention.

A zipper 50 is secured in the cover 40 to assist with inserting the mattress 10 core comprised of the various layers 20, 30, and optionally 22, 24 and 32. In the illustrated embodiment, the zipper 50 is disposed along at least a portion of the periphery of the bottom surface 46 of the cover 40.

FIGS. 6-12 are various illustrations of a mattress 10 of the present invention. FIG. 6 illustrates a mattress 10 shown in a folded and compressed state and stored in a box. In this illustration, the box has been opened to remove the mattress 10, as would be done for shipping. FIG. 7 illustrates the mattress 10 of FIG. 6 having been removed from the box. After the packaging has been removed from the mattress 10, it begins to decompress and then unfold, as illustrated in FIGS. 8 and 9, until it lies flat, as illustrated in FIGS. 10-12. In FIGS. 10-12, the mattress 10 is installed on a conventional bed frame. 

We claim:
 1. A mattress including: a base layer constructed from a responsive polymer structure and defining a top surface, a bottom surface, and a perimeter wall between said top surface and said bottom surface; and a top layer fabricated from a vertically-oriented synthetic memory fiber blend and defining a top surface, a bottom surface, and a perimeter wall between said top surface and said bottom surface, said top layer bottom surface being secured to said base layer top surface in a conventional manner.
 2. The mattress of claim 1 wherein said base layer responsive polymer structure is fabricated from a foam material defining an Indentation Level Deflection (ILD) Rating of between about 25 and about 35 pounds.
 3. The mattress of claim 1 wherein said base layer defines a thickness of between four and eight inches (4″-8″).
 4. The mattress of claim 1 wherein said base layer has a density of between about one and about four pounds per cubic feet (˜1 to ˜4 lb/ft³).
 5. The mattress of claim 1 wherein said vertically-oriented synthetic memory fiber blend is comprised of bi-copolymer fibers and fibers having spring-like molecular structure.
 6. The mattress of claim 1 wherein said top layer defines a thickness of between 0.75″ and 1.25″.
 7. The mattress of claim 1 wherein said top layer defines a weight of between about 200 to about 500 grams per square yard.
 8. The mattress of claim 1 further comprising at least one intermediary layer defining a top surface, a bottom surface, and a perimeter wall between said top surface and said bottom surface, said at least one intermediary layer being disposed between said base layer and said top layer; wherein said base layer top surface is secured to said at least one intermediary layer bottom surface in a conventional manner; and wherein said at least one intermediary layer top surface is secured to said top layer bottom surface in a conventional manner.
 9. The mattress of claim 8 wherein said at least one intermediary layer is fabricated from a foam material.
 10. The mattress of claim 8 wherein said at least one intermediary layer includes: a first intermediary layer defining a top surface, a bottom surface, and a perimeter wall between said top surface and said bottom surface; and a second intermediary layer defining a top surface, a bottom surface, and a perimeter wall between said top surface and said bottom surface; wherein said base layer top surface is secured to said first intermediary layer bottom surface in a conventional manner; wherein said first intermediary layer top surface is secured to said second intermediary layer bottom surface in a conventional manner; and wherein said second intermediary layer top surface is secured to said top layer bottom surface in a conventional manner.
 11. The mattress of claim 10 wherein each of said first intermediary layer and said second intermediary layer is constructed from a foam material having a highly-open, cool, and responsive polymer structure.
 12. The mattress of claim 10 wherein each of said first intermediary layer and said second intermediary layer defines a thickness of about 1.5″ to about 3″.
 13. The mattress of claim 10 wherein each of said first intermediary layer and said second intermediary layer is constructed of a foam material defining an ILD Rating of between about 10 and about
 25. 14. The mattress of claim 13 wherein said first intermediary layer ILD Rating is greater than said second intermediary layer ILD Rating.
 15. The mattress of claim 10 wherein each of said first intermediary layer and said second intermediary layer has a density of between about two and about four pounds per cubic feet (˜2 to ˜4 lb/ft³).
 16. The mattress of claim 1 further comprising a cover member configured to closely and selectively receive at least said base layer and said top layer, said cover member including a conventional closure member to allow for selective removal of said cover, said cover member being provided with at least one handle for assisting in movement and transport of said mattress.
 17. The mattress of claim 1 further comprising a cover layer defining a top surface, a bottom surface, and a perimeter wall between said top surface and said bottom surface, said cover layer being disposed above said top layer, being fabricated from a selected foam material, and defining a thickness of up to about one inch (1″).
 18. The mattress of claim 17 wherein said top layer top surface is secured to said cover layer bottom surface in a conventional manner.
 19. The mattress of claim 17 further comprising a cover member configured to closely and selectively receive at least said base layer, said top layer and said cover layer, said cover member including a conventional closure member to allow for selective removal of said cover, said cover member being provided with at least one handle for assisting in movement and transport of said mattress.
 20. A mattress including: a base layer constructed from a responsive polymer structure and defining a top surface, a bottom surface, and a perimeter wall between said top surface and said bottom surface, said responsive polymer structure being fabricated from a foam material defining an Indentation Level Deflection (ILD) Rating of between about 25 and about 35 pounds, said base layer defining a thickness of between four and eight inches (4″-8″), and having a density of between about one and about four pounds per cubic feet (˜1 to ˜4 lb/ft³); a first intermediary layer defining a top surface, a bottom surface, and a perimeter wall between said top surface and said bottom surface, said base layer top surface being secured to said first intermediary layer bottom surface in a conventional manner, said first intermediary layer being constructed from a foam material defining an ILD Rating of between about 10 and about 25 and having a highly-open, cool, and responsive polymer structure, said first intermediary layer defining a thickness of about 1.5″ to about 3″, said first intermediary layer having a density of between about two and about four pounds per cubic feet (˜2 to ˜4 lb/ft³); and a second intermediary layer defining a top surface, a bottom surface, and a perimeter wall between said top surface and said bottom surface, said first intermediary layer top surface being secured to said second intermediary layer bottom surface in a conventional manner, said second intermediary layer being constructed from a foam material defining an ILD Rating of between about 10 and about 25 and having a highly-open, cool, and responsive polymer structure, said second intermediary layer defining a thickness of about 1.5″ to about 3″, wherein said first intermediary layer ILD Rating is greater than said second intermediary layer ILD Rating, said second intermediary layer having a density of between about two and about four pounds per cubic feet (˜2 to ˜4 lb/ft³); a top layer fabricated from a vertically-oriented synthetic memory fiber blend comprised of bi-copolymer fibers and fibers having spring-like molecular structure, said top layer defining a top surface, a bottom surface, and a perimeter wall between said top surface and said bottom surface, said top layer bottom surface being secured to said base layer top surface in a conventional manner, said top layer defining a thickness of between 0.75″ and 1.25″ and a weight of between about 200 to about 500 grams per square yard, said second intermediary layer top surface is secured to said top layer bottom surface in a conventional manner; a cover layer defining a top surface, a bottom surface, and a perimeter wall between said top surface and said bottom surface, said cover layer being disposed above said top layer, being fabricated from a selected foam material, and defining a thickness of up to about one inch (1″); a cover member configured to closely and selectively receive said base layer, said first intermediary layer, said second intermediary layer, said top layer, and said cover layer, said cover member including a conventional closure member to allow for selective removal of said cover, said cover member being provided with at least one handle for assisting in movement and transport of said mattress. 